Siding assembly structure

ABSTRACT

A siding material suitable for affixing to a substrate or sheeting wherein such siding material consists of two principal portions. An underlay and overlay portion are each respectively joined to one another by means of a suitable fastener, such as a rivet. The rivet is attached through mating holes on the respective portions, where such holes are provided with sufficient clearance with respect to the rivet, so as to enable vertical and horizontal adjustment of the overlay with respect to the underlay once the entire unit has been affixed to the substrate. The advantage of such adjustment derives results from an ability of the installed siding to exhibit a flat face contour rather than a concave or &#39;&#39;&#39;&#39;oil canned&#39;&#39;&#39;&#39; configuration which is unpleasing to the eye.

United States Patent 1191 Bettoli 1451 Aug. 13, 1974 SIDING ASSEMBLY STRUCTURE [75] Inventor: Phillip Stephen Bettoli, Martinsville,

[73] Assignee: GAF Corporation, New York, NY.

[22] Filed: Feb. 20, 1973 [211 App]. No.: 334,136

Prima'ry Examiner-Frank L. Abbott Assistant Examiner-Carl D. Friedman Attorney, Agent, or Firm-Walter C. Kehm; Samson B. Leavitt [57] ABSTRACT A siding material suitable for affixing to a substrate or sheeting wherein such siding material consists of two principal portions. An underlay and overlay portion are each respectively joined to one another by means of a suitable fastener, such as a rivet. The rivet is attached through mating holes on the respective portions, where such holes are provided with sufficient clearance with respect to the rivet, so as to enable vertical and horizontal adjustment of the overlay with respect to the underlay once the entire unit has been affixed to the substrate. The advantage of such adjustment derives results from an ability of the installed siding to exhibit a flat face contour rather than a concaveor oil canned configuration which is unpleasing to the eye.

7 Claims, 3 Drawing Figures 1. SIDING ASSEMBLY STRUCTURE The present invention is directed to a siding material suitable for use in surfacing exterior walls and roofs of dwellings. In particular, the present invention is directed to a multi-component assembly which utilizes two separate parts to form the finished unit in the form of a clapboard or shingle type of surfacing material.

The use of siding as exterior surfacing material for dwellings is by no means new. However, there are a number of critical problems which have been associated with the use of siding materials and have in some manner or another created adverse problems which will be explained hereinafter below. Siding material produced from plastics such as polyvinyl chloride resins are fabricated usually by extrusion as one entire unit. With such construction, there are certain limitations that can adversely affect performance as well as cost. For example, with siding material of the type mentioned above, there is a problem associated with high thermal expansion. Such characteristics tend to restrict the choice of colors that can be employed, i.e., only white and light pastel colors are presently commercially offered so as to avoid excessive temperature rise resulting from exposure to solar energy. If such exposure does take place, and the temperature is sufficiently elevated, a severe case of buckling results. In turn, distortion related to the increase in dimensions and relief of stresses received during fabrication of the as installed unit causes an unpleasing looking installation.

Furthermore, since the siding after being fastened to the substrate is unable to expand vertically after positioning on the dwelling unit the face of the installation becomes concave.

Another problem relates to the manner of manufacture of siding materials. In this connection, it is difficult to extrude wide, non-uniform, thin profiles of thermplastics that exhibit stress-free internal characteristics. These stresses are relieved at elevated temperature and in doing so, cause additional distortion or oil canning of the flat face portions of the siding.

To reduce these problems, manufacturers employ complex die designs; this in turn tends to reduce the rate of extrusion and without much doubt, production rates are held significantly below that of operations where cross-sections for similar gauge product are utilized. Obviously, with such complex extrusion arrangements for the manufacture of such products, the amount of product produced per unit time is substantially less than with a product having a uniform crosssection (everything else being equal). Lastly, die costs are higher for profile cross-sections than for a uniform cross-section which can be post formed.

Another important characteristic of the materials being presently employed for siding, relates to its inefficient usage. Since most siding material on the market is formed as a unitary structure, the unexposed portion of the finished product (that which is overlapped by a successive course of siding) consists of the same material as the exposed portion, that is: such portions of the siding contain the same pigments, stabilizers, resins and other components needed for resistance to weathering, when in fact such areas of the product are not actually exposed to the elements. The underlay portion of the siding material is not exposed to the stringent weather conditions as is the exterior portions, and obviously it follows that the material employed for unerlay could certainly consist of less costly components and yet provide the same essential characteristics as the presently available material.

In addition, another shortcoming in the prior art is the inability to efficiently employ laminates; that is, by co-extrusion of two different compositions. This is particularly true for thin cross sectional units of different sizes and shapes required for different siding materials. Such a manufacturing limitation severely restricts the advantages that are available through co-extrusion of the siding materials. The aforementioned difficulty applies to shingles and clapboard exterior material which are fabricated by post-forming metals or plastic flat sheet stock.

Accordingly, it is the main object of the present invention to develop a siding material free of the defects of the prior art.

It is still a further object of the present invention to provide a siding assembly which employs a twocomponent arrangement to allow for relative motion between both of the units so as to avoid the defects of the prior art.

Still .a further object of the present invention is to provide a vinyl siding material which when installed exhibits a flat plane rather than concave siding contour.

Another object is to employ a two-part siding material having a fastener for joining such parts adapted to allow for controlled vertical and horizontal movement between the respective parts after being installed on a substrate.

Still another object of the present invention is to provide an interlock arrangement that may be disposed on either the major or minor portion of the two-part siding unit.

A further object of the present invention is to provide a two-component, one piece unit, requiring no joining of the separate portions of the siding material once such material is at theinstallation site.

Another object of the present invention is the elimination of the'need to align subsequent courses of siding after installation of the initial course.

Still another object of the present invention is to employ a two-element structure material employing an inexpensive and strong underlay material to reduce manufacturing costs, while simultaneously increasing production time.

Other objects of the invention will be apparent from the following description, it being understood that the above general statements of the objects of my invention are intended to describe and not limit in any manner.

It has-been discovered that with the two-part siding assembly arrangement the underportion can be fabricated from less expensive material such as, resins, without the need to employ pigment and ultra-violet light stabilizers. Since such portion is not exposed to the elements, it follows that control of color and surface texture is not required for the underlay materials. Sheet metal or other conventional materials may be employed for this purpose so as to provide the necessary strength and rigidity to the exterior siding portion.

' Resin compositions with lower co-efficients of expansion allow operators with less skill than heretofore re quired, for the application and installation of the siding. On the other hand, with conventional plastic siding, the fasteners, i.e., nails, must be driven to an exacting degree of tightness and sufficiently large allowances must be made in order to take thermal expansion into account after the siding material has been installed and set in place.

The present invention also contemplates that the overlay or exposed portion can be fabriated from flat sheet material by extrusion or calendaring and joined to the underlay so that one portion can he slid laterally with respect to the other and not create any undesirable stresses when the siding is affixed to the substrate. It is submitted that this type of arrangement will eliminate the lengthwise restraints on the exposed outer portion and distortion due to expansion is greatly minimized or eliminated.

In accordance with the present invention, it has been found that the exterior portion of the two part assembly can be formed from a rigid monolithic extrusion of thermplastic material such as highly pigmented polyvinyl chloride. The actual manufacturing of such siding can be from a sheet material having a uniform crosssection, while employing extrusion techniques to produce the underlay portion. Fabrication from a sheet of uniform cross-section is particularly desirable when extrusion is employed to produce the overlaying section. Plastic flow rates at various sections of the die tend to be more uniform and less stresses are created when uniform cross-sections are fabricated. The exposed portion of the two-part siding arrangement may be made from laminate sheet such as an ABS surfaced with a durable exterior coating or film. Acrylic base paints or pigmented acrylic film or pigmented polyvinyl chloride film and PVD film can also be employed as suitable protective surfacing materials. Suitable materials for the underlay or substrate portion can be: polypropylene, ABS resins, aluminum, polyvinyl chloride, nylon, polystyrene, etc.

It has been found that composite extrusions of polyvinyl sheet from a dual slit die can be utilized to achieve good performance at less cost. In such case, the exposed surface side can be formulated for excellent durability and color choice while the underlay composition may consist of an unpigmented resin with less light stabilizer and-obviously lower cost per running foot. The overall geometricrelationship of the interconnecting parts can vary. For example, the cross-sectional thickness of the outer portion can be varied depending, however, upon the material employed. In general, the thickness must be adequate to resist impact and other surface forces; when utilizing polyvinyl chloride, a thickness of 0.040 to 0.045 inches has been found satisfactory (when impact modifiers have been incorporated in the composition).

The actual locking means and the associated relationship as between the overlay and the underlay portions for joining the two members can take different forms and arrangements. However, it is essential in all cases, to provide a joining system which permits horizontal movement of the overly with respect to the underlay portions, especially when the latter is fixed to the building surfaces. In this connection, a principle similar to a hook and eye, ball and socket, interlocking hooks, etc. are all suitable.

To enable vertical adjustment of the overlay and underlay portions with respect to one another, a suitable fastening means such as: a rivet, is employed to mating holes on the respective portions of the siding material. The rivet provides affirmative affixing between such portions while at the same time a predetermined amount of clearance is provided as between such holes and the rivet to enable adjustment of the external siding portion with respect to the underlay. Such adjustment ultimately provides a flat plane face to the siding rather than the conventional concave or oil canned surface.

The principal features of the present invention are directed to a siding material suitable for affixing to a substrate or sheeting wherein such siding material consists of two principal portions. An underlay and overlay portion are each respectively joined to one another by means of a suitable fastener, such as a rivet. The rivet is attached through mating holes on the respective portions, where such holes are provided with sufficient clearance with respect to the rivet, so as to enable vertical and horizontal adjustment of the overlay with respect to the underlay once the entire unit has .been affixed to the substrate. The advantage of such adjustment derives results from an ability of the installed siding to exhibit a flat face contour rather than a concave or oil canned configuration which is unpleasing to the eye.

Referring to the drawings:

FIG. 1 is a side elevation, partially in section of the invention.

FIG. 2 is an exploded view of the invention.

FIG. 3 is a fragmentary view of an alternate embodiment.

In the drawings, FIG. 1 illustrates in perspective the invention which includes a two-portion siding material 1 employing a rivet 2 for holding such portions together. The siding material 1 is applied to a substrate S by fastening means such as a nail 3 through suitable nailing slots (See FIG. 2) provided in the secondary or underlay portion 4. The underlay portion 5 is affixedly attached to a primary or overlay portion 6 by means of suitable fastening means such as rivets 2. Mating holes in the overlay and underlay portions respectively, 7, 8 are provided to allow for the rivet 2 to pass through such holes and affix the relationship with respect to the underlay and overlay portions. A suitable predetermined clearance 9 of holes 7 and 8 with respect to the diameter of the shank portion of the rivet 10 is so selected as to allow for adequate movement of the overlay and underlay portions with respect to one another as a basis for adjustment of such portions. At all times, the primary portion and secondary or underlay portion are connected and act as a unitary structure from the moment such materials leave the manufacturing facility until when they are in stalled on site. Suitable fastening means for attaching respective courses of siding material are provided through the locking arrangement such as a hook type flange 11 on the outer portion of the underlay portion 4 cooperating with a flange member 12 which is disposed on the underside of the overlap portion 6.

An alternate embodiment shown in FIG. 3 illustrates how a variation on the aforementioned locking arrangement can be employed where the flange l 1 is disposed beneath the rivets 2 on the underlay 6 of the siding material. Obviously, in order to properly position the flange 12' with respect to the flange 11 and yet maintain the esthetic quality of the siding, the flange 11 has to be so designed as to engage and yet cover over any of the nailing holes shown in the underlay portion 5'. The locking arrangements for interconnecting respective courses of siding material can vary depending upon the particular application involved. The essential features of such a locking arrangement must relate to the ability to engage the flange 12' into the flange 11 and yet permit sufficient movement through the rivets 2 via holes 7 and 8. During actual installation a series of underlay portions 5 would be fastened to the side of the building or suitable substrate and then the next course of siding material is engaged in the flange 11 via the lower flange 12' and is'locked into position. Once the siding is permanently fastened by nails 3 through the holes 4 there is sufficient clearance to enable relative vertical and horizontal adjustment for thermal expansion. In all instances, the aforementioned arrangement'joining the primary portion to the underlay allows for a flat plane face to exist during extreme thermal expansion conditions by allowing for suitable clearance after installation.

Thus, there have been shown above what at present are considered preferred embodiments of the invention. It will be obvious that many changes and modifications are possible without departing from the scope thereof.

I claim:

1. A two part siding assembly for attachment in parallel overlapping courses to a substrate, comprising, in combination, an overlay portion with a first edge and a second edge having a series of fastening holes formed therein adjacent said first edge, and a flange member formed therein adjacent said second edge; an underlay portion for attachment to the substrate having a series of nailing holes for such purpose, a series of fastening holes in alignment with the fastening holes of the overlay portion, and locking means disposed between said series of nailing holesand fastening holes adapted to engage and secure the flange member ofthe overlay portion of an adjacent overlapping course; and fastening means disposed within the fastening holes of the overlay and underlay portions to secure the same together and permit relative movement therebetween, to allow for thermal expansion and contraction of both portions. 1

2. A siding assembly in accordance with claim 1, in which the fastening holes of the overlay and underlay portions are larger in size than the fastening means to permit said relative movement.

3. A siding assembly according to claim 2, in which the fastening means comprises a plurality of rivets.

4. A siding assembly in accordance with claim 1, in which the overlay portion has a greater thickness than the underlay portion.

5. A two-part siding assembly for attachment in parallel overlapping courses to a substrate, comprising, in combination, an overlay portion with a first edge and a second edge having a series of fastening holes formed therein adjacent said first edge, a flange member formed adjacent said second edge, and locking means formed therein adjacent said series of fastening holes adapted to engage and secure the flange member of the overlay portion of an adjacent overlapping course; and an underlay portion for attachment to the substrate having a series of nailing holes for such purpose, and a series of fastening holes in alignment with the fastening holes of the overlay portion; and fastening means disposed within the fastening holes of the overlay and un- 

1. A two part siding assembly for attachment in parallel overlapping courses to a substrate, comprising, in combination, an overlay portion with a first edge and a second edge having a series of fastening holes formed therein adjacent said first edge, and a flange member formed therein adjacent said second edge; an underlay portion for attachment to the substrate having a series of nailing holes for such purpose, a series of fastening holes in alignment with the fastening holes of the overlay portion, and locking means disposed between said series of nailing holes and fastening holes adapted to engage and secure the flange member of the overlay portion of an adjacent overlapping course; and fastening means disposed within the fastening holes of the overlay and underlay portions to secure the same together and permit relative movement therebetween, to allow for thermal expansion and contraction of both portions.
 2. A siding assembly in accordance with claim 1, in which the fastening holes of the overlay and underlay portions are larger in size than the fastening means to permit said relative movement.
 3. A siding assembly according to claim 2, in which the fastening means comprises a plurality of rivets.
 4. A siding assembly in accordance with claim 1, in which the overlay portion has a greater thickness than the underlay portion.
 5. A two-part siding assembly for attachment in parallel overlapping courses to a substrate, comprising, in combination, an overlay portion with a first edge and a second edge having a series of fastening holes formed therein adjacent said first edge, a flange member formed adjacent said second edge, and locking means formed therein adjacent said series of fastening holes adapted to engage and secure the flange member of the overlay portion of an adjacent overlapping course; and an underlay portion for attachment to the substrate having a series of nailing holes for such purpose, and a series of fastening holes in alignment with the fastening holes of the overlay portion; and fastening means disposed within the fastening holes of the overlay and underlay portions to secure the same together and permit relative movement therebetween, to allow for thermal expansion and contraction of both portions.
 6. A siding assembly in accordance with claim 5, in which the fastening holes of the overlay and underlay portions are larger in size than the fastening means to permit said relative movement.
 7. A siding assembly in accordance with claim 6, in which the fastening means comprises a plurality of rivets. 